Mallory Print is a family-owned custom embroidery company based in Joshua, TX, serving the DFW Metroplex and shipping nationwide. We embroider logos, names, and artwork onto caps, trucker hats, beanies, and visors for businesses, teams, schools, and events — in-house, start to finish.
Custom embroidered hats are one of the most effective pieces of branded apparel a business can invest in. They travel with whoever wears them. They’re worn outside work hours. They show up in social media photos without anyone planning it. Done well, a great embroidered hat works harder than almost any other promotional product — and the only way to do it well is with quality embroidery, not a heat-pressed logo that curls at the edges after two washes.
The most popular style for branded hats. A firm, structured front panel gives the design a clean, stable surface to work with — ideal for embroidered logos that need crisp definition and consistent sizing.
Mesh-back trucker hats carry a specific look that works well for agricultural businesses, outdoor brands, construction companies, and lifestyle-adjacent organizations. The foam front panel is embroidery-friendly.
Flat-brim and curved-brim caps in both snapback and fitted styles. Popular with younger audiences, sports teams, schools, and streetwear-aligned brands.
Embroidery on beanies requires specialized digitizing because knit fabric stretches. Our in-house digitizing team accounts for this in every beanie order.
Open-top visors for golf events, outdoor sports, and summer activations. Embroidery sits on the front panel cleanly and consistently.
A growing category for events, resort wear, and youth-facing brands. Bucket hats can carry embroidery on the front panel and the brim.
Three things determine whether a custom embroidered hat looks like it came from a reputable company or looks like it was made on a budget: digitizing quality, thread quality, and garment quality. We control all three in-house.
Digitizing quality is the most important factor and the one most often overlooked. A logo designed for print looks completely different when you try to stitch it at 2 inches wide on a curved hat panel. Small text fills in. Fine lines disappear. Gradients become flat blobs. Our embroidery digitizing team builds each stitch file specifically for the garment and size — not a one-size-fits-all conversion.
Thread quality affects color vibrancy, durability, and sheen. We use commercial-grade embroidery thread across all orders and match colors to your brand standards as closely as possible.
Garment quality matters because the hat is the first thing someone sees — before they even get to the embroidery. We source from quality hat manufacturers and will match you with the right style, structure, and price point for your use case.
Embroidered hat orders come from across DFW and from customers shipping nationwide. Common use cases include:
Branded hats for crews and job site teams.
Staff outfitting and merchandise for members.
Spirit wear hats across Johnson County raising funds.
Coaching staff, volunteers, and team gear.
Hats as commemorative giveaways or participant gifts.
Employee gifts, new hire swag, or trade show giveaways.
Hats for volunteers, mission teams, and fundraising events.
Merchandise that carries the brand into everyday life.
The two main alternatives to embroidery on hats are heat transfer printing and patch application. Each has its place, but embroidery is the durable, professional standard for most branded hat applications.
Embroidery stitches the design directly into the fabric of the hat. It doesn’t peel, fade, or crack. It looks premium from ten feet away. It’s the method that golf courses, corporate teams, and professional sports organizations use because it holds up and communicates quality.
Heat transfer applies a printed film to the hat’s surface. It works for designs with very fine detail or photographic elements that embroidery can’t reproduce, but it’s not as durable as embroidery on items that get heavy daily wear.
Embroidered patches are a middle-ground option — patches digitized and stitched separately, then applied to the hat. This works well for designs that aren’t practical to stitch directly onto curved hat panels.
Our team will help you choose the right method for your artwork, your timeline, and your budget.
Vector files (.AI, .EPS, .PDF with embedded vectors) are the best starting point for embroidery digitizing. If you have a raster file (.PNG, .JPG), send it over and we’ll assess what we’re working with. Our in-house graphic design team can rebuild or clean up artwork before the digitizing process begins.
Embroidery has size and detail limits that print doesn’t. Very small text (under a quarter inch tall), extremely fine lines, and complex gradients simplify when stitched at hat-appropriate sizes. Our digitizing team will flag any detail concerns before production and suggest adjustments that preserve your brand’s intent without compromising embroidery quality.
Yes. Side panels and back panels are common secondary placements — often used for a secondary logo, tagline, or website URL. We’ll factor additional placements into your quote.
Contact us at (817) 558-0804 or ethan@malloryprint.com for a quote based on your quantity, style, and design complexity. We’ll be straightforward about pricing at every quantity level.
In many cases, yes. Contact us with the hat details and we’ll confirm they’re compatible with our in-house embroidery process before you commit to anything.
Quality embroidery on a quality hat should outlast the hat itself under normal wear conditions. There’s no finish to peel or ink to fade — just thread sewn into fabric. The most common causes of embroidery failure are poor digitizing and low-quality thread. We use neither.
Yes. Mallory Print has shipped custom embroidered apparel and hats to customers across all 48 continental states. Place your order remotely — submit artwork by email, approve your proof digitally, and we’ll ship directly to you.
Call (817) 558-0804 or email ethan@malloryprint.com. Monday–Friday, 8:00 AM–5:00 PM. Mallory Print — Joshua, TX — a four-generation Mallory family business, shipping custom embroidered hats nationwide.
